Ceiling tile

ABSTRACT

The present invention is directed to a ceiling panel for use in a suspended ceiling system. The ceiling panel includes a main frame and at least two crossing members within said main frame. A facing material is adhered to the main frame and crossing members.

TECHNICAL FIELD AND INDUSTRIAL APPLICABILITY OF THE INVENTION

This invention relates to suspended ceiling tiles which are fitted intoa conventional ceiling grid system.

BACKGROUND OF THE INVENTION

U.S. Pat. No. 3,782,495 discloses a thin, lightweight suspended ceilingtile. The tile includes a wire frame over which a thin skin, i.e.,aluminum foil or thin plastic film, is applied. The edges of the skinare wrapped around the wire frame and are secured by adhesive.

U.S. Pat. No. 6,499,262 illustrates a suspended ceiling structureincluding a rectangular grid and a plurality of panels supported on thegrid. The panels are assemblies of a rigid perimeter frame, a fabricsheet, sound absorbing material, and sound transmission attenuatingmaterial. The fabric sheet forms the visible face of the panel when itis installed in the ceiling grid. The frame includes side members whichare preferably formed as extrusions of thermoplastic material, such aspolyvinyl chloride. Suitable materials for the fabric include polyester,polyolefin, vinyl-coated fabric or acrylic fabric.

U.S. Pat. No. 4,580,387 illustrates a corrosion resistant gridconstruction for suspended ceiling. A portion of two cross members arejoined by a junction clip to either side of main members. The main andcross members are formed in an inverted T configuration. A flangeextends from either side of a base web which support ceiling panels.Main and cross members also support the ceiling members.

U.S. Pat. No. 3,186,129 discloses a ceiling structure having a pluralityof rectangular panels each having two layers of translucent polyvinylchloride plastic material which are stretched over the upper and loweredges of a rectangular sheet metal frame. The panels are supported on astrip-metal gridwork having rectangular openings. The metal strips onthe grid are of a T-shape to that the panels can be easily located onthe horizontal surfaces.

U.S. Pat. No. 3,460,299 illustrates a suspended ceiling having aplurality of rectangular window openings, constructed of wood or metal,bounded by wood or metal flanges for receiving and supporting the edgesof luminous ceiling panels. The ceiling panels are made of a translucentmaterial which diffuses light such as flexible plastic films made ofpolyester, vinyl, acrylic, polyethylene, or terephthalate.

In the past, suspended ceilings have been constructed of wood or metalmaterials, which are heavy and high in cost. There is a need for animproved, low-cost, suspended ceiling panel system constructed oflightweight materials that permit easy installation while providing anaesthetically pleasing appearance.

SUMMARY OF THE INVENTION

These needs are met by the present invention, wherein an improvedceiling panel for a suspended is provided. The ceiling panel includes amain frame having at least two crossing members within said main frame.The ceiling panel is preferably constructed of injected molded plasticand is a one-piece design. A facing material, preferably a veil, fabricor textile, is adhered to the main frame and crossing members. Theceiling panel fits in a conventional suspended ceiling grid system andhides pipes, cables and unfinished ceilings.

It is an object of the present invention to provide a ceiling panel thatis lightweight providing for easy handling and installation.

It is another object of the present invention to provide a ceiling panelfor a suspended ceiling system that is low in cost without impactingaesthetics.

It is another object of the present invention to provide a ceiling panelthat is easy to manufacture.

It is another object of the present invention to provide a ceiling panelthat provides acoustical benefits to a suspended ceiling system.

Other objects and advantages of the present invention will becomeapparent upon considering the following detailed description andappended claims, and upon reference to the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is plan view of the support frame for a ceiling panel of thepresent invention

FIG. 2 is a plan view of the ceiling panel of the present invention.

FIG. 3 is a side view of the ceiling panel of the present invention

FIG. 4 is a side view of another embodiment of the ceiling panel of thepresent invention.

DETAILED DESCRIPTION AND PREFERRED EMBODIMENTS OF THE INVENTION

The present invention is directed to a ceiling panel for use in asuspended ceiling system. The ceiling panel includes a main frame and atleast two crossing members within said main frame. A facing material isadhered to the main frame and crossing members.

Referring now to FIG. 1, support frame 2 includes main frame 4 andcrossing members 6 and 8. Crossing member supports 10 provide stabilitywhere crossing members 6 and 8 contact the frame 4. It is preferable forthe support frame 2 to be a one-piece frame, however, frame 4 andcrossing members 6 and 8 may be manufactured separately, assembled intwo or more pieces and then welded together by a plastic or metalwelding process.

FIG. 1 shows a square support frame, however, the support frame may beany shape suitable for use in a suspended ceiling system. For example,the support frame may be circular, rectangular, triangular, etc. FIG. 1shows two crossing members 6 and 8. In certain instances, there may bemore than two or several crossing members depending on the size of theceiling panel. The crossing members are not limited to an “X” shape, asshown in FIG. 1. For example, crossing members may cross one other in a“T” shape.

Support frame 2 is preferably made of plastic and formed by an injectionmolding process or an extrusion process. Suitable materials for thesupport frame include, but are not limited to, polyethylene, polyvinylchloride, polypropylene, polystyrene, nylon, acrylic, polycarbonate andother plastics. The support frame 2 may be constructed of a plasticreinforced with other materials such as glass fibers, carbon fibers,mica, wollastonite and talc and may comprise a binder such as an acrylicor styrene based binder.

Support frame 2 may also be made by an air or gas assistedinjection-molding process. The typical process involves gas or air beinginjected into the hot core of the plastic melt through a nozzle, ordirectly into the molding cavity of the frame via one or more gasneedles. Due to an almost constant pressure in all areas with gaspenetration, a good and even pressure distribution and transmission isguaranteed across the molded part. After the end of the gassing phase,the pressure is released either by gas recycling or blowing the gas intothe atmosphere. As soon as ambient pressure is reached, the molded framecan be ejected. Hollow pockets in the frame, created by this process,maintain flexural stiffness of the frame and, in turn, providesubstantial cost savings.

It is preferable for the plastic to contain a flame retardant materialsuch as halogenated additives/copolymers, antimony trioxide, antimonypentoxide, nitrogen-phosphorous, phosphates, aluminum trihydrate,magnesium hydroxide, bauxite or calcium carbonate.

Alternatively, the support frame 2 and crossing members 6 and 8 may beconstructed of roll-formable metals including, but not limited to,aluminum, steel, copper, tin or coated metals such as clad, galvanized,prefinished, preplated, prepainted, vinyl laminated and tin platedcoated metals.

Referring now to FIG. 2, ceiling panel 12 is shown including supportframe 2 including main frame 4, crossing members 6 and 8 and facing 14which covers support frame 2. Preferably, facing 14 is a veil, textile,fabric, polymeric film, foils, laminates or other non-woven or wovenfacer. The facing 14 may contain glass wool or glass fibers to provideacoustical benefits to the ceiling.

In an alternative embodiment, the ceiling panel 12 may be made in onepiece, including the frame and the facing material. The ceiling panel 12is formed from a multi-layer product including an insulating layer and astructural layer, the structural layer comprising a reinforcedcomposite. The insulating layers preferably contain a phenolic binder.The layers are laminated together via a standard compression moldingprocess. The resulting product includes a lofted facing for insulatingagainst the transmission of sound and heat energy and the frame, i.e.,the structural layer. Preferably, the multi-layer material used isAcoustimax™ material manufactured by Owens Corning, Toledo, Ohio.

Referring now to FIG. 3, a side view of the support frame 16 and facing18 is shown. Facing 18 extends across the entire length of support frame16 and is preferably affixed to the support frame by heat bonding. Inthe heat bonding process, one side of support frame 16 is heated andsoftened. The facing 18 is then affixed to the softened side of thesupport frame 16 and, upon cooling, the facing 18 is firmly adhered tothe support frame 16.

Adhesives can also be used to affix the facing 18 to the support frame16. Adhesive may be applied to either the facing 18, the support frame16 or both. Common adhesives include epoxy adhesives, polyurethane andhot melt adhesives.

FIG. 3 illustrates a ceiling tile having a support frame 16, which issubstantially flat and can be easily fit into a suspended ceiling framesystem. FIG. 4 shows an alternative support frame 20 having edges 24, 26which can be fitted into a suspended ceiling system. Facing 28 isaffixed to extending portion 28 of support frame 20.

While the invention has been described in terms of preferredembodiments, it will be understood, of course, that the invention is notlimited thereto since modifications may be made by those skilled in theart, particularly in light of the foregoing teachings.

1. A ceiling panel for use in a suspended ceiling system comprising: a)a main frame; b) at least two crossing members within said main frame;and c) a facing material adhered to said main frame and said crossingmembers.
 2. The ceiling panel of claim 1, wherein said main frame andsaid crossing members a one-piece assembly.
 3. The ceiling panel ofclaim 2, wherein said main frame and said crossing members are made of amaterial selected from the group consisting of injection molded plasticand extruded plastic.
 4. The ceiling panel of claim 2, wherein said mainframe and said crossing members are made of a material selected from thegroup consisting of aluminum, steel, and other roll-formable metals. 5.The ceiling panel of claim 3, wherein said main frame and said crossingmembers are welded together.
 6. The ceiling panel of claim 3, whereinsaid plastic is flame retardant.
 7. The ceiling panel of claim 6,wherein said plastic is selected from the group consisting of rigidpolyvinyl chloride and polyphenylene sulfide.
 8. The ceiling panel ofclaim 6, wherein said plastic is a plastic made with a material selectedfrom the group consisting of halogenated additives/copolymers, antimonytrioxide, antimony pentoxide, nitrogen-phosphorous flame retardants,phosphates, aluminum trihydrate, magnesium hydroxide, bauxite, andcalcium carbonate.
 9. The ceiling panel of claim 3, wherein said plasticis reinforced with a material selected from the group consisting ofglass fibers, carbon fibers, mica, wollastonite, and talc.
 10. Theceiling panel of claim 1, wherein said facing material is a veil. 11.The ceiling panel of claim 1, wherein said facing material is a textilematerial.
 12. The ceiling panel of claim 1, wherein said facing materialis a film.
 13. The ceiling panel of claim 5, wherein said facingmaterial is adhered to said main frame and said first and secondcrossing members by heat bonding or through adhesives applied either tothe frame or preapplied to the veil.
 14. The ceiling panel of claim 1,wherein said main frame is square or rectangular.
 15. The ceiling panelof claim 14, wherein said crossing members are arranged in an “X” shapeor radiated outwardly from a centrally located, circular connectionpoint.
 16. The method of making a ceiling panel for use in a suspendedceiling system comprising the steps of: a. providing a main frame b.providing first and second crossing members within said main frame; c.providing a facing material; and d. affixing said facing material tosaid main frame and said first and second crossing members.
 17. Themethod of claim 16, wherein said main frame and said crossing membersare a one-piece assembly.
 18. The method of claim 17, wherein said mainframe and said crossing members are made of a material selected from thegroup consisting of injection molded plastic and extruded plastic. 19.The method of claim 17, wherein said main frame and said crossingmembers are made of a material selected from the group consisting ofaluminum, steel, and other roll-formable metals.
 20. The method of claim18, wherein said main frame and said crossing members are weldedtogether.
 21. The method of claim 18, wherein said plastic is flameretardant.
 22. The method of claim 21, wherein said plastic is selectedfrom the group consisting of rigid polyvinyl chloride and polyphenylenesulfide.
 23. The method of claim 21, wherein said plastic is a plasticmade with a material selected from the group consisting of halogenatedadditives/copolymers, antimony trioxide, antimony pentoxide,nitrogen-phosphorous flame retardants, phosphates, aluminum trihydrate,magnesium hydroxide, bauxite, and calcium carbonate.
 24. The method ofclaim 18, wherein said plastic is reinforced with a material selectedfrom the group consisting of glass fibers, carbon fibers, mica,wollastonite, and talc.
 25. The method of claim 16, wherein said facingmaterial is a veil.
 26. The method of claim 16, wherein said facingmaterial is a textile material.
 27. The method of claim 16, wherein saidfacing material is a film.
 28. The method of claim 20, wherein saidfacing material is adhered to said main frame and said first and secondcrossing members by heat bonding or through adhesives applied either tothe frame or preapplied to the veil.
 29. The method of claim 16, whereinsaid main frame is square or rectangular.
 30. The method of claim 29,wherein said crossing members are arranged in an “X” shape or radiatedoutwardly from a centrally located, circular connection point.